Expandable mandrel for use in friction stir welding

ABSTRACT

A mandrel that provides a counter-force to the pressure exerted on the outside of a pipe or other arcuate surface by a friction stir welding tool, wherein the mandrel is expandable through the use of a wedge, and wherein the mandrel enables multiple friction stir welding heads to simultaneously perform welding on the arcuate surface.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to friction stir welding. Morespecifically, the present invention addresses improvements in theability to perform friction stir welding of pipe or other arcuateobjects, wherein a mandrel is needed to provide a counter-balancingforce against the inside of the arcuate surface being welded, to therebyprevent a friction stir welding tool in contact with the outside of thearcuate surface from damaging the workpiece being welded.

2. Description of Related Art

Friction stir welding (hereinafter “FSW”) is a technology that has beendeveloped for welding metals and metal alloys. The FSW process ofteninvolves engaging the material of two adjoining workpieces on eitherside of a joint by a rotating stir pin or spindle. Force is exerted tourge the spindle and the workpieces together and frictional heatingcaused by the interaction between the spindle and the workpieces resultsin plasticization of the material on either side of the joint. Thespindle is traversed along the joint, plasticizing material as itadvances, and the plasticized material left in the wake of the advancingspindle cools to form a weld.

FIG. 1 is a perspective view of a tool being used for friction stirwelding that is characterized by a generally cylindrical tool 10 havinga shoulder 12 and a pin 14 extending outward from the shoulder. The pin14 is rotated against a workpiece 16 until sufficient heat is generated,at which point the pin of the tool is plunged into the plasticizedworkpiece material. The workpiece 16 is often two sheets or plates ofmaterial that are butted together at a joint line 18. The pin 14 isplunged into the workpiece 16 at the joint line 18.

The frictional heat caused by rotational motion of the pin 14 againstthe workpiece material 16 causes the workpiece material to softenwithout reaching a melting point. The tool 10 is moved transverselyalong the joint line 18, thereby creating a weld as the plasticizedmaterial flows around the pin from a leading edge to a trailing edge.The result is a solid phase bond 20 at the joint line 18 that may begenerally indistinguishable from the workpiece material 16 itself, incomparison to other welds.

It is observed that when the shoulder 12 contacts the surface of theworkpieces, its rotation creates additional frictional heat thatplasticizes a larger cylindrical column of material around the insertedpin 14. The shoulder 12 provides a forging force that contains theupward metal flow caused by the tool pin 14.

During FSW, the area to be welded and the tool are moved relative toeach other such that the tool traverses a desired length of the weldjoint. The rotating FSW tool provides a continual hot working action,plasticizing metal within a narrow zone as it moves transversely alongthe base metal, while transporting metal from the leading face of thepin to its trailing edge. As the weld zone cools, there is typically nosolidification as no liquid is created as the tool passes. It is oftenthe case, but not always, that the resulting weld is a defect-free,recrystallized, fine grain microstructure formed in the area of theweld.

Previous patent documents have taught the benefits of being able toperform friction stir welding with materials that were previouslyconsidered to be functionally unweldable. Some of these materials arenon-fusion weldable, or just difficult to weld at all. These materialsinclude, for example, metal matrix composites, ferrous alloys such assteel and stainless steel, and non-ferrous materials. Another class ofmaterials that were also able to take advantage of friction stir weldingis the superalloys. Superalloys can be materials having a higher meltingtemperature bronze or aluminum, and may have other elements mixed in aswell. Some examples of superalloys are nickel, iron-nickel, andcobalt-based alloys generally used at temperatures above 1000 degrees F.Additional elements commonly found in superalloys include, but are notlimited to, chromium, molybdenum, tungsten, aluminum, titanium, niobium,tantalum, and rhenium.

It is noted that titanium is also a desirable material to friction stirweld. Titanium is a non-ferrous material, but has a higher melting pointthan other nonferrous materials.

The previous patents teach that a tool is needed that is formed using amaterial that has a higher melting temperature than the material beingfriction stir welded. In some embodiments, a superabrasive was used inthe tool.

The embodiments of the present invention are generally concerned withthese functionally unweldable materials, as well as the superalloys, andare hereinafter referred to as “high melting temperature” materialsthroughout this document.

Recent advancements in friction stir welding (FSW) technologies haveresulted in tools that can be used to join high melting temperaturematerials such as steel and stainless steel together during the solidstate joining processes of friction stir welding.

As explained previously, this technology involves using a specialfriction stir welding tool. FIG. 2 shows a polycrystalline cubic boronnitride (PCBN) tip 30, a locking collar 32, a thermocouple set screw 34to prevent movement, and a shank 36. Other designs of this tool are alsoshown in the prior art of the inventors, and include monolithic toolsand other designs.

When this special friction stir welding tool is used, it is effective atfriction stir welding of various materials. This tool design is alsoeffective when using a variety of tool tip materials besides PCBN andPCD (polycrystalline diamond). Some of these materials includerefractories such as tungsten, rhenium, iridium, titanium, molybdenum,etc.

The inventors have been the leader in developing friction stir weldingtechnology for use with high melting temperature alloys such as steel,stainless steel, nickel base alloys, and many other alloys. Thistechnology often requires the use of a Polycrystalline cubic boronnitride tool, a liquid cooled tool holder, a temperature acquisitionsystem, and the proper equipment to have a controlled friction stirwelding process.

Once the technology had been established (current literature indicatesthe state of the technology) as a superior method for joining thesematerials, MegaDiamond and Advanced Metal Products (working together asMegaStir Technologies) began searching for applications that wouldgreatly benefit from this technology. One of the largest applicationsfor friction stir welding (FSW) is joining pipe lines. Joining pipe lineis extremely costly because of the manpower and equipment needed to weldand move needed components. FIG. 3 shows the manpower and equipmentneeded to fusion weld a typical pipeline. The pipe 40 is shown with aplurality of welding stations 42 (each of the white enclosures) that areneeded to lay down progressive layers of welding wire to create a fusionwelded joint between segments of pipe.

Advanced high strength steels (AHSS) are being implemented into pipelines because less material is needed, higher strength properties areobtained and the total pipeline cost can be lower. The difficulty withAHSS lies in the conventional fusion welding methods being used. It isaccepted in the industry that every pipe line joint contains a defect orcrack. These defects are accepted because they cannot be eliminated evenwith sophisticated automated fusion welding systems. Welding AHSS is farmore difficult than existing pipe line steels because the materialcomposition inherently causes more fusion welding defects.

FSW has now been established as a viable technology to join pipesegments. A friction stir welding machine 50 to join pipe segments hasbeen developed as shown in FIG. 4. A rotating tool plunges into a jointas it creates frictional heat. Once the tool has plunged into theworkpiece cross section, the tool is caused to travel circumferentiallyaround the pipes while the joint is “stirred” together. The FSW tool isthen retracted and the machine 50 is moved along the pipe to the nextpipe joint to be friction stir welded.

The friction stir welding machine 50 shown in FIG. 4 illustrates themachine that operates on the exterior of the pipe being welded. One ofthe requirements of FSW in any form is to have a counter-balancing forceon the back side (opposite the tool) of the workpiece being joined. Thisneed arises from the large forces that are applied by the tool againstthe workpiece. The nature of friction stir welding requires that somesupport be provided to prevent the workpiece from bending or otherwisebeing damaged. FIG. 5 shows the current design of a rotating mandrel 60or “pipe pig” that is currently being used when a friction stir weldingpipe.

The mandrel 60 is hydraulically actuated to follow the tool path on theinside of the pipe as the tool follows circumferentially around the pipejoint on the exterior. When the pipe joint is complete, the mandrel 60is reconfigured so that it can be moved to the next pipe joint. Whilethis mandrel 60 is an effective means to provide support on the oppositeside of the tool, the hydraulics and controls are expensive and theconstruction of the pipe is therefore also costly. A mandrel 60 for FSWof a 12 inch pipe diameter using this design also weighs about 800 lb.This means that moving the mandrel requires additional equipment andsupport. A further disadvantage is that this mandrel configuration mustalso have additional hydraulics and rams added to align two pipesegments, further adding to the weight of the mandrel 60. While thisdesign is workable in the field, it would be preferable to have alighter weight and lower cost mandrel design that can add to the speedand reduce the cost of FSW of a pipeline.

Accordingly, what is needed is a less expensive, less complex, andlightweight pipe pig that can be more easily deployed on-site.

BRIEF SUMMARY OF THE INVENTION

It is an object of the present invention to provide an expandablemandrel that is less complex than those used in the prior art.

It is another object to provide an expandable mandrel that is lighter inweight and therefore easier to use than those used in the prior art.

It is another object to provide an expandable mandrel that can easilymove along a length of a pipe in order to reposition itself for use insubsequent friction stir welding operations on-site.

The present invention is a mandrel that provides a counter-balancingforce to the pressure exerted on the outside of a pipe or other arcuatesurface by a friction stir welding tool, wherein the mandrel isexpandable through the use of a wedge, and wherein the mandrel enablesmultiple friction stir welding heads to simultaneously perform weldingon the arcuate surface.

These and other objects, features, advantages and alternative aspects ofthe present invention will become apparent to those skilled in the artfrom a consideration of the following detailed description taken incombination with the accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a perspective view of a tool as taught in the prior art forfriction stir welding.

FIG. 2 is a perspective view of a removable polycrystalline cubic boronnitride (PCBN) tip, a locking collar and a shank.

FIG. 3 is a perspective view of a plurality of welding stations that areneeded to lay down progressive layers of welding wire to create a fusionwelded joint between segments of pipe in the prior art.

FIG. 4 is a perspective view of a friction stir welding machine that iscapable of joining pipe segments.

FIG. 5 is a perspective view of a current design of a rotating mandrel“pipe pig” currently being used when friction stir welding pipe.

FIG. 6 is a perspective view of a mandrel shell.

FIG. 7 is a perspective view of a mandrel shell having attached lips forexpanding a gap.

FIG. 8 is a perspective view of a mandrel shell showing the means forexpanding the gap in the mandrel shell.

FIG. 9 is a cross-sectional perspective view of a mandrel shell and themeans for expanding the gap in the mandrel shell.

FIG. 10 is a cross-sectional perspective view of a mandrel shell and themeans for expanding the gap in the mandrel shell, disposed inside apipe.

FIG. 11 is an end view of a mandrel shell showing a system of cable andpins for closing the gap when the expanding wedge is retracted.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made to the details of the invention in which thevarious elements of the present invention will be described anddiscussed so as to enable one skilled in the art to make and use theinvention. It is to be understood that the following description is onlyexemplary of the principles of the present invention, and should not beviewed as narrowing the claims which follow.

The presently preferred embodiment of the invention is an expandablemandrel for use in friction stir welding operations on arcuate surfacessuch as pipe. An expandable mandrel concept was developed that proved tobe simple, light weight, and inexpensive. The construction of themandrel is shown in the following steps.

FIG. 6 shows a first embodiment of a mandrel shell 72 that forms anouter shell of the mandrel or “pipe pig” 70 of the present invention.The mandrel shell 72 is a hollow cylinder having an opening or gap 74along the length thereof. The diameter of the mandrel shell 72 isselected so that the mandrel shell will slide inside of the pipesegments (not shown) that are to be welded, when the gap 74 is allowedto close.

FIG. 6 also illustrates relief cuts 76 that are made on the insidediameter 78 of the mandrel shell 72 so that the mandrel shell can springand flex at the locations of the relief cuts 76. Once the mandrel shell72 is machined, lips 80 are welded into place on the inside diameter 78of the mandrel shell 72 immediately adjacent to the gap 74 as shown inFIG. 7.

Once the lips 80 have been welded into place, the mandrel shell 72 isfurther modified so that the gap 74 is naturally in a closed positionwhen there is no external force being applied to the mandrel shell. Thisclosing of the gap 74 is accomplished by running a fusion weld bead, asis known to those skilled in the art, parallel to the length of therelief cuts 76, and in equiangular positions relative to each other. Inother words, enough weld beads are disposed on the inside of the mandrelshell 72 in uniform locations to distort the mandrel shell so that thegap 74 is closed as a result of the residual stresses caused by thesolidifying weld beads. Thus, the mandrel shell 72 now springs back to aclosed position if the gap 74 is forced apart.

In FIG. 8, the next component of the pipe pig 70 is to provide amechanism whereby the mandrel shell 72 can be caused to expand and openthe gap 74 when needed. Accordingly, an expanding wedge 82 is providedso that it can be inserted between the lips 80 of the mandrel shell 72.Note that the angle of the expanding wedge 82 that makes contact withthe lips 80 is constructed to easily allow the expanding wedge to moveupwards into the gap 74, and thereby cause the gap to continue to widenas long as the expanding wedge can be pushed against the lips 80.

Expansion of the mandrel shell 72 stops when the expanding wedge 82makes contact with the inside of a pipe, or when the outside diameter ofthe mandrel shell 72 can no longer expand outwards against the insidediameter of a pipe.

FIG. 8 also illustrates a platform or plate 84, and a plurality ofhydraulic cylinders 86 that are disposed on the plate. The hydrauliccylinders 86 push against the plate 84 and the expandable wedge 82 tocause the expandable wedge to move upwards into the gap 74. It isenvisioned that the bottom of the hydraulic cylinders 86 could also bemodified so as to fit the inside of the mandrel shell 72. However, asthe mandrel shall is designed to expand and contract, the bottom of thehydraulic cylinders 86 would need to be able to compensate for the shiftin shape.

It should be noted that a single hydraulic cylinder 86 could be used inplace of the plurality of hydraulic cylinders being shown. Furthermore,the length of the mandrel shell 72, the lips 80, the expandable wedge82, and the plate 84 can all be modified depending upon the requiredapplication. Thus, a system that is smaller in length may be useful inapplications where the space or length of horizontal sections within apipe are restricted.

Similarly, the length of the components listed above might be expandedto enable multiple tools to simultaneously be used to perform frictionstir welding on a pipe while the pipe is supported by the single pipepig 70.

FIGS. 9 and 10 show how the expanding wedge 82 is positioned to slideoutwards through the lips 80 of the mandrel shell 72 if the gap 74 islarge enough to accommodate the expanding wedge when the gap is as wideas it can be. FIG. 9 is a cross-sectional view of the invention thatalso shows the hydraulic cylinders 86 in cross-section. FIG. 10 is across-sectional view that shows all the elements shown in FIG. 9, butwith the addition of a pipe 90. This figure also shows a joint 96 thatis the seam between the pipes being friction stir welded.

FIG. 10 shows the expanding wedge 82 fully inserted between the lips 80.When hydraulic pressure is removed from the hydraulic cylinders 86, themandrel shell 72 retracts and the mandrel shell springs closed. Themandrel shell 72 can now be moved to a different location within thepipe 90. The mandrel shell 72 is moved to the next pipe joint where itis expanded. Hydraulic hoses and fittings that lead to the hydrauliccylinders 86 are not shown. However, these hoses and fittings aredisposed on an end of the mandrel shell 72 so that they are coupled tothe hydraulic cylinders 86.

It is noted that not only does the pipe pig 70 provide thecounter-balancing force necessary for friction stir welding of the pipe90, but it can also function to further align the segments of the pipe90

It is also noted that the plate 84 that supports the hydraulic cylinders86 is coupled to the mandrel shell 72 so the expanding wedge 82 can beretracted from the gap 74 instead of lifting the plate.

The following are modifications that can be made to the mandrel shell 72design above that can enhance the operation of the pipe pig 70. Forexample, holes can be machined through the mandrel shell 72 so that aircan flow through the holes when the mandrel shell is collapsed. Thiscreates an “air bearing” on the bottom of the mandrel shell 72 so thatone person can easily slide the pipe pig 70 to the next pipe joint thatis to be friction stir welded.

Another aspect of the invention is that quick disconnects can be used onthe hydraulic hoses that are coupled to the hydraulic cylinders 86 sothat the hoses can be quickly disconnected and reconnected when the pipepig 70 is re-positioned at a next pipe joint.

In another aspect of the invention, a variety of materials can be usedto construct the mandrel shell 72. Spring steel could be used to alwaysmaintain the relaxed closed position of the mandrel shell 72. Thematerial must always be in the elastic region and not be easily stressrelieved. This way, the mandrel shell 72 will always keep its shape. Ifthe mandrel shell does start to lose its shape and spring outward whenin a relaxed position so that the gap 74 is visible, more welding beadscan be run along the length of the inside diameter to restore theresidual stresses that cause the mandrel shell 72 to close.

Another aspect of the invention is that expanding wedges can be made indifferent sizes to compensate for different tolerances of pipe segments.

Another aspect of the invention is that coatings (TiN, TiCN, etc.) canbe used on an outer surface of the mandrel shell 72 to thereby preventthe pipe joint from diffusion welding to the mandrel shell duringfriction stir welding.

Another aspect of the invention is that the invention can be used forany diameter pipe.

It is noted that a rod is attached (not shown) that feeds hydraulichoses through the next section of pipe.

Another aspect of the present invention has to do with a means forpulling the mandrel shell 72 closed when in a relaxed position. As shownin FIG. 11, the expanding wedge 82 can include posts or pins 92 and acable 94 disposed therebetween. The cable 94 is run around a pin 92 onboth lips 80 of the mandrel shell 72. When the expanding wedge 82 isretracted, the cable 94 performs the function of pulling on the two lips80 so that they are forced to come together and close the gap 74. It isanticipated that this system of pins 92 and cable 94 can be disposed onboth ends of the mandrel shell 72 if needed.

It is to be understood that the above-described arrangements are onlyillustrative of the application of the principles of the presentinvention. Numerous modifications and alternative arrangements may bedevised by those skilled in the art without departing from the spiritand scope of the present invention. The appended claims are intended tocover such modifications and arrangements.

1. A mandrel for use in friction stir welding of a pipe, said mandrelcomprising: a mandrel shell formed as a hollow cylinder having an outerdiameter that is smaller than an inner diameter of the pipe, wherein thecylinder has a gap therein that is perpendicular to a top edge and abottom edge; a means for expanding the mandrel shell such that the gapwidens to a desired width, the means comprising at least one hydraulicactuation device; and a wedge coupled to the at least one hydraulicactuation device and disposed so as to widen the gap by being insertedinto the gap when the at least one hydraulic actuation device isactuated; and two lips welded onto the inside diameter of the mandrelshell, each lip disposed adjacent to and on either side of the gap suchthat the wedge contacts both lips as the wedge is inserted into the gapand continues to be pressed against the lips, wherein the wedge slidesoutwards through the two lips and the mandrel shell continues to expanduntil the wedge or the mandrel shell makes contact with the inside ofthe pipe.
 2. The mandrel as defined in claim 1 wherein the at least onehydraulic actuation device is a hydraulic cylinder.
 3. The mandrel asdefined in claim 1 wherein the at least one hydraulic actuation devicefurther comprises a platform on which the at least one hydraulicactuation device can rest.
 4. The mandrel as defined in claim 3 whereinthe platform is further comprised of a plurality of holes disposedtherethrough.
 5. The mandrel as defined in claim 1 wherein the mandrelis further comprised of a plurality of relief cuts in the insidediameter of the mandrel, wherein the relief cuts are perpendicular tothe top and bottom edges of the mandrel.
 6. The mandrel as defined inclaim 1 wherein each of the lips is tapered away from each other and thegap.
 7. The mandrel as defined in claim 1 wherein the gap in the mandrelshell is closed when the mandrel shell is at rest.
 8. The mandrel asdefined in claim 7 wherein the mandrel shell has residual stresses thatcause the mandrel shell to be closed at the gap.
 9. The mandrel asdefined in claim 8 wherein the residual stresses are created bydisposing a plurality of fusion weld beads parallel to the gap andspaced equidistantly from each other in the mandrel shell.
 10. Themandrel as defined in claim 1 wherein the size of the expanding wedgecan be modified so as to cause the mandrel to expand more when a largerexpanding wedge is used, and to cause the mandrel shell to expand to alesser degree when a smaller expanding wedge is used, to therebyaccommodate different diameter pipes using the same mandrel shell. 11.The mandrel as defined in claim 1 wherein an outer diameter of themandrel shell is coated with a material to prevent a pipe from diffusionwelding to the mandrel shell during friction stir welding.
 12. Themandrel as defined in claim 1 wherein the mandrel is further comprisedof a means for coupling edges of the gap to the wedge, whereinretracting the wedge from the gap causes the edges of the gap to movetoward each other.